Kazakhstan Balkhash Copper Concentrator

1938, Barr initially positioned hash Mining copper sulfide ores are processed Коунрадск containing 4% Cu in the deposit. From the beginning of 1972, ore beneficiation plant also processes Саякск deposits. In 1989, the annual capacity of the ore processing plant reached a maximum of 14.4 million tons.

By 1989, due to the sharp decline in ore reserves, including the East Коунрадск copper- molybdenum ore that had been mined since 1942, copper concentrate production declined. The amount of ore processed in 1997 was 2.8 million tons, and the annual output of mineral copper was 12,700 tons.

Under the existing pharmaceutical system and process conditions, the Коунрадск ore with a copper grade of 0.32% to 0.34% (with a cut-off grade of 0.20%) can be treated with a copper recovery rate of 78%. In 1997 Concentrator after incorporation Казахмыс (Kazakhmys) shares of the company to step up treatment of copper metallurgical slag, to solve the problem of expanding the raw material base.

In 1998, the concentrator stopped processing the Коунрадск ore and only processed the ore and copper metallurgical production waste from the Саякск deposit. At this time, in the industrial organization of waste slag mining, during the period 1998-1999, copper recovered from the waste metallurgical slag accounted for 67% of the total recovered copper.

By the end of the metallurgical slag field excavation phase in May 2000, the concentrator resumed processing the Коунрадск ore. In addition, the concentrator also processes the ore of the Шатыркурклъск deposit. Industrial tests were carried out on the ore of the Нурказканск deposit from October 2003. In 2004, the concentrator began to process the smelting slag.

At present, 8 systems of the concentrator process copper-molybdenum ore and 1 smelting furnace slag of 4 deposits (Table 1).

Table 1 Benha indicator of Balhash concentrator

In order to successfully select these unusual blends, it is necessary to use a suitable ore preparation process and crushing and grinding process control that takes into account the characteristics of the raw material process.

As we all know, the ККД-1500/180 conical coarse crusher is suitable for the feeding of the largest block of 1200mm. When feeding the smelting slag, the feeding may pass quickly. In order to prevent the flat feeder from being crushed, the frequency adjustment is installed. To adjust the speed of the flat feeder.

A square hole (20mm × 20mm) rubber sieve plate was installed on the sifter in the medium and fine crushing workshop to replace the 36mm round hole metal sieve plate, thereby increasing the operation rate of the screening machine.

In order to reduce the over-grinding of the new brittle large ore, a three-stage grinding process is adopted: the first section of the two rod mills is directly fed into the second section of the ball mill ; in the second section of the grinding, 2 is used. The billiard mill and the cyclone are closed; in the third section of the grinding, a billiard mill is used, which is also closed with the cyclone.

The grinding media was optimized: a steel bar with a diameter of 100 mm was added to the first section of the rod mill, and steel balls of 60 and 40 mm diameter were used in the second and third stage ball mills.

The rod mill adopts a fast working system. Therefore, in the rod mill transmission, the shaft of the Z=17 is replaced by the shaft with the transmission ratio Z=20.

Taking these measures can stabilize the particle size of the flotation feed to the level of 55%-65%-0.074mm.

The selectivity of each type of ore and its mixed ore samples was preliminarily studied under laboratory conditions. The amount of the agent is determined based on the composition of the ore. In the flotation process, the inhibition by Lime choice â…¡ pyrite. The high residual concentration of lime may inhibit the flotation of copper sulfide minerals. In order to reduce the loss of copper, the in-tank product of the selected I is fed into the cyclone for classification. The lithos rich in pyrite are discarded into the tailings dam, and the overflow of the cyclone is given to the roughing operation.

Research work has shown that pulp intensification is very effective. Filling the first flotation cell with air reduces the amount of lime by half.

In order to improve the flotation reagent system, some new collectors selective for copper minerals were tested. In all cases, the grade of concentrate copper increased, the copper recovery rate decreased and the cost of the agent increased. In the case of applying the backwater from the concentrator, the effect of the above agent is further reduced. The best results were obtained when applying the own xanthate collector.

After the copper smelter changed the production process - smelting with Βанюков furnace, the concentrator treated the blowing slag. Separating magnetite from slag is a key issue.

In the flotation test, the finely ground slag is magnetically selected in advance. At this time, the magnetic product yield was 62.19%, and the copper recovery rate was 51.34%, and the magnetite recovery rate was 88.86% (Table 2).

Table 2 Magnetic smelting results of copper smelting slag

When copper concentrate obtained by flotation flotation was separated by magnetic separation method (copper recovery rate of 89.53%, magnetite recovery rate of 25.76%), 8.66% of copper and 80.9l% of magnetite were transferred The magnetic separation concentrate contains 1.60% Cu and 19.4% magnetite. The recovery rate of copper concentrate copper to ore is 81.78% (economic estimates show that it is cost-effective to treat smelting slag when copper recovery is 86%).

The test found that the comprehensive utilization of raw materials has increased: magnetite concentrates have been obtained from the flotation tailings of the Саякск ore and Шатыркурклъск ore, which is a by-product of the concentrator.

The current work direction is to obtain molybdenum-containing products from various ores and products processed, but the separation flotation process used in the past cannot remove the carbon contained in the mixed concentrate. Currently, two decarburization schemes have been developed: low temperature roasting plus flotation or conversion of molybdenum sulfide to molybdenum dioxide.

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